BOLLETTINO TECNICO N• 139-129 

The technical content of this document is approved 

under the authority of OOA nr. EASA 21 J.OOS DATE June 3, 2008 

Compliance with 

this bulletm is: 

SUBJECT: COCKPIT DOORS WINDOWS REPLACEMENT 

REV. 

REASON: Some cases of in flight breakage of cockpit doors windows have been 

reported in service. This Bollettino provides the necessary instructions to 

upgrade the aircraft configuration with an improved design. 

NOTE 

This Boii<Stt,no supersedes BT 139-087 Rev A 

HELICOPTERS AFFECTED: AB139/AW139 helicopters from SIN 31005 to S/N 31131 

(except S/N 31007, 31094 and 31124), from SIN 31201 to SIN 31209 and 

from S/N 41001 to S/N 41013 (except S/N 41012). 

COMPLIANCE: within 200 FH or 6 months from receipt of this Bollettino, whichever 

comes first 

DESCRIPTION: This Bollettino prescribes the replacement of the cockpit doors 

windows with a more robust design. 

Moreover an additional strap to allow immediate jettison in emergency is 

installed together with a new external placard. 

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Page 1 of 19 
B.T. 139-129 Rev./ 

In order to expedite parts availability to the customer, for the time being also 

the aircraft having the optional LHS sliding windows will receive a plain LHS 

improved window for the upgrade. This is reflected in the list of required 

materials. 

REQUIRED MANPOWER: It is estimated that in order to accomplish this Bollettino four 

(4) man-hours are necessary. 

Man-hours are based on hands-on time and may vary w1th personnel and facilities 

available. 

WARRANTY: 

./ Upon request, the parts required to apply this Bollettino shall be supplied on a free of 

charge basis by Agusta, except for the consumable materials . 

./ Upon application of this Bollettino, Customers are requested to submit to Agusta 

Warranty Administration a Maintenance Malfunction Information Report duly 

completed in all its parts. 

REQUIRED MATERIALS: the following materials, necessary to accomplish this 

bollettino, can be required to AgustaWestland: 

PIN DESCRIPTION Q.TY 

3P5211A48131A1 (1) Storm Window Assy RHS 1 

3P5211A 1 0152A 1 ( 1) Cockpit Door Window LHS 

212-072-636-109 Decal 2 

999-1700-48-1 01 G (2) Seal AR 

3G5610A04751 Strap 2 

MS35207 -230 Bolt 2 

A436A06A2 Nut 2 

A994A15T010D Washe· 4 

Moreover, the following consumable materials, necessary to accomplish this bollettino. 

can be required to AgustaWestland: 

Page 2 of 19 
B.T. 139-129 Rev. I 

PIN DESCRIPTION Q.TY 

590210190 (2) Cloth, CCC-C-46 (C011) 

900002980 (2) Adhesive, RTV 732, 199-05-152 Ty. I cl. II (C126) AR 

32002675 (2) Solvent, commercial, Methyl-ethyl-ketone (MEK) (C005) AR 

531050415 Ethyl Alcohol, commercial AR 

590160418 Abrasive Paper, P-C-451 , 320 grit grade (C017) AR 

SPECIAL TOOLS: the following special tools are required to accomplish this Bollettino: 

PIN DESCRJPTJON Q.TY 

3G5605G00132 Tool kit, windows installation (GF-94-00) 1 

composed by· 

3G5605G00251 Hook, seal expander .1 

3G5605G00551 (3) Tool, seal wedge installation .1 

Local supply (2) Plastic scraper 1 

Local supply Non alcoholic pencil 1 

Local supply Hand saw 1 

Local supply Clamp 1 

Customer must order the tools to AgustaWestland, if required . 

Notes: (1) Contact AW139 Customer Support Engineering 

(aw 39 mbx(W,aqustawc:;stla'ld cc...-;) for details on optional LHS storm 

windows and spare parts. 

(2) Depending on existing seal condition. Refer to step 6. 

(3) Tool P/N CP293 can be used as an alternative to P/N 3G5605G00551. 

WEIGHT AND BALANCE CHANGES: N.A. 

REFERENCES: 

.; AW139 Material Data Information (AMDI) 

../ AW139 Aircraft Maintenance Publication (AMP) 

../ AW139 Illustrated Tools and Equipment Publication (ITEP) 

Page 3 of 19 
B.T. 139-129 Rev./ 

PUBLICATIONS AFFECTED: 

./ AW139 Aircraft Maintenance Publication (AMP) 

./ AW139 Illustrated Parts Data (IPD) 

./ AW139 Rotorcraft Flight Manual (RFM) 

COMPLIANCE INSTRUCTIONS: 

1. Prepare the helicopter for a safe ground maintenance. Disconnect the battery and all 

the electrical power sources and/or the external power supply. Refer to AMP, see 

data module no 39-A-00-20-00-00A-120A-A. 

2. With reference to figure 1, gain access to the cockpit door window (1) on the left side 

of the aircraft. 

3. With reference to figure 1, remove the cockpit door window (1) as follows: 

3.1 Remove the red strap (3) from the clinch stud (7). 

3.2 Pull the red strap (3) and fully remove the filler wedge (5) from the seal (6) 

3.3 Hold the transparent (2) to make sure that it does not fall down. 

CAUTION 

iVlal<e sure you do 11ot daMage the transnarent w'1en 

you ret'OVe it &roill door. It wil' be use•u! :o help 1ew 

cock;Jit door window installation. 

3.4 Carefully push the transparent (2) inboard. Remove the transparent (2) from 

the seal (6). Do not remove the seal (6) from the door structure (4). 

4. Do a visual inspection of the seal for damage and condition. 

4.1 If you find that the seal is damaged or cut. replace the seal with a new one as 

described at step 5. 

4.2 If you find that the seal is in good condition. go to step 6. to check the new door 

window dimension. 

5 With reference to figure 3. install a new seal P/N 999-1700-48-101 G as follows 

Page .11 of 19 

WARNiNG 

THE so:_ VENT (CC05) JS A DAN GE~OUS 

it~ =~IAL. 8E!= ~E YOU USE lT, lii!AK!: SURE 

n-'AT vou KNOW ALL THE SAFETY 
B.T. 139-129 Rev./ 

PRECAUTIONS AND FiRST A!D INSTRUCTIONS 

FOR THIS MATERIAL. REFER TO AMD! (SEE 

DATA MODULE N. 39-A-00-50-00-00A-074A-D). 

5.1 If necessary, remove the rubber particles with the Plastic Scraper. Clean the 

seal seat on the door structure with the Cloth (C011) and the Solvent (COOS). 

Dry the cleaned area with the clean cloth. 

CAUTION 

With reference to figure 2, make sure that the seal 

and the filler wedge length is 2320 mm. 

5.2 Make a little mark at the middle of the top window frame. Cut the seal PIN 999-

1700-48-101 G and keep it at the middle with your hands. 

5.3 Clean the seal with ethyl alcohol before installation. Make sure that the seal 

grooves are free from dirt. 

WARNING 

THE ADHESIVE (C126) IS A DANGEROUS 

MATERIAL. BEFORE YOU USE IT, MAKE SURE 

THAT YOU KNOW ALL THE SAFETY 

PRECAUTIONS AND . FlRST AID INSTRUCT! ON$ 

FOR THIS MATERIAL. REFER TO AMDI (SEE 

DATA MODULE N. 39-A-00-50-00-00A-074A-D). 

5.4 With reference to figures 3 and 4, bond the groove of the seal over the whole 

perimeter on fuselage side only with Adhesive (C126). 

NOTE 

5.5 Carefully put the seal on the door structure. Start fmm the middle top of the 

window frame. Make sure that the middle of the seal is aligned with the mark 

on the window frame. Refer to figure 2 to check the correct seal position. 

Page 5 of 19 
B.T.139-129 Rev./ 

CAUTION 

Do not pu'' :he seal w'-,i'e you ;'lstall ·: o., t~e ~~'J~ 

structu'"e. Be careful whe'l you l'lsta' ' the sea o- ~:...o 

curves of t1e window f~arne 

5.6 At the end of the installation you have the seal butt joint at the middle bottom of 

the window frame. Refer to figure 2 to check the correct seal position. 

CAUTION 

- he bu~ joirt must have no clearance between he 

two seal heads 

5. 7 If there is clearance between the two seal heads, contact AW-139 Customer 

Support Engineering (aw139.mbx@agustawestland.com). 

6. Prepare new window P/N 3P5211 A 1 0152A 1 as follows: 

---:::. '=I\ 

6.1 Put the transparent removed at step 3. on a work bench. 

6.2 (Applicable to storm windows) With reference to figure 5, do as follows: 

6.2.1 Remove the two screws (2) and the screw (3). 

6.2.2 Remove the three nuts (6). 

6.2 3 Remove the stop (5) and the washers (7) and (8). 

6.2.4 Remove the handle assy (4) from the storm window (1). 

6 3 Put a suitable paper sheet (whose surface is bigger than the cockpit window 

area) on the transparent. Make sure that it adheres perfectly to the transparent 

surface. 

Page 6 of 19 
B.T. 139-129 Rev./ 

6.4 Using the transparent as a template, draw its contour on the paper sheet. 

6.5 Put the new transparent on the paper sheet (remove the handle assy as 

described at step 6.2 in case it is a storm window). Use clamps in places 

previously recorded to make the paper sheet adhere perfectly on the 

transparent surface. 

6.6 According to the contour drawn on the paper sheet, sign the new boundary with 

a non alcoholic pencil on the new transparent, if required. 

6. 7 Remove the transparent from the paper sheet and place it on a suitable bench. 

CAUTION 

Do not engrave the transparent. 

6.8 Trim the transparent to the new marked contour. Use a hand saw (and NOT a 

circular automatic saw) to cut the material in excess. 

6.9 (Applicable to storm windows) With reference to figure 5, install the handle assy 

(4) on the storm window (1) using hardware removed at step 6.2. 

6.10 With reference to figure 9 and figure 10 section Z-Z, install strap P/N 

3G561 OA04751 on the transparent using bolt P/N MS35207 -230, nut P/N 

A436A06A2 and two washers P/N A994A15T0100. 

7. With reference to figure 3, install the cockpit door window in the groove of the seal 

as follows: 

7.1 Clean the cockpit door window with ethyl alcohol and grind with abrasive paper 

(C017) on internal and external side by a depth of 5 mm. Remove sharp 

corners from the window. Chamfering is allowed up to a maximum of 0.5 mm. 

7.2 Put the cockpit door window in its position against the seal. Hold the cockpit 

door window and, at the same time, lock the cockpit door with your hands. 

7.3 Open the lip of the seal with the Hook P/N 3G5605G00251 . Start from the top 

and carefully install the cockpit door window in the seal. Continue until all the 

window edge is in the groove of the seal. 

8. With reference to figure 1, install the filler wedge in the related groove of the seal as 

follows: 

8.1 Keep the filler wedge at its middle with your hands. 

8.2 Clean the filler wedge with ethyl alcohol before installation. 

Page 7 of 19 
B.T. 139-129 Rev. / 

8.3 With reference to figure 1, put the filler wedge (5) in the related eyelet of the red 

strap (3). Move the red strap (3) in the middle position of the filler wedge (5). 

CAUTION 

An improoer usage of the seal wedge installatior tool 

can cause dar~age to the seal. It is suggested to get 

used to the filler installation procedure oefore 

aoolying it on the window. Refe' to figu:-e 6 for 

details_ 

CAUTION 

Do not pull the filler wedge to make its installation 

easier. 17 you pull it a deformation wil' occur a!o1g the 

filler wedge contour. T'1is deformation decreases the 

seal s:rergth 

CAUTION 

Do not oull the filler wedge while you 1nstal' ~~ i'"' •'le 

sea'. Do not ~orque t~e filler wedge wher you i-rstal' 

i: h he curves of ~he seal 

8.4 Carefully put the filler wedge in the related groove of the seal with the Tool P/N 

3G5605G00551 . Start from the middle bottom of the seal and go on until the 

fi ller wedge is near the black strap position. Refer to figures 7 and 8 for details. 

8.5 With reference to figures 9 and 10, insert the filler wedge in the related eyelet of 

the black strap P/N 3G561 OA4751. Adjust the black strap position as required 

and go on with fil ler wedge installation. 

8.6 At the end of installation you have the seal butt joint in position indicated in 

figure 2. Refer to figure 2 to check the correct filler wedge position. 

CA~riON 

8.7 If there is clearance between the two filler heads. contact AW1 39 Customer 

Support Engineering (aw139.mbx@agustawestland.com). 

9. With reference to figure 1, attach the red strap (3) to the clinch stud (7). 

Page 8 of 19 
B.T. 139-129 Rev./ 

10. With reference to figure 11 , do as follows: 

10.1 Remove decal PIN A181A001E1 (1) from cockpit door window internal side. 

Refer to AMP, see OM no 39-A-11 -00-01-00A-5208-A. 

10.2 Replace decal P/N 999-2701 -45-509 (2) with new one P/N 212-072-636-109 on 

cockpit door external side. Refer to AMP, see OM no 39-A-11-00-01-00A-520AA and OM no 39-A-11 -00-01-00A-720A-A. 

11. With reference to figure 1, gain access to the cockpit door window (1) on the right 

side of the aircraft and repeat steps 3. thru 10. to install the right cockpit door 

window P/N 3P5211A48131A1. 

12. Return helicopter to flight configuration and record for compliance of this bollettino. 

Page 9 of 19 
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f\gure '\ 

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0 I'(P\CAL 

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I 

7 
SEAL BUTT JOINT 

B.T. 139-129 Rev. I 

A - I 

... i 

A 

EXTRACTION STRAP 

! 

0 ' 

.qN 

' FILLER WEDGE 

BUTT JOINT 

NOTE: LENGTH OF COCKPIT DOOR WINDOW FILLER WEDGE 

MUST BE 2320 mm 

Figure 2 

Page 11 of 19 
B.T. 139-129 Rev./ 

CLEAN WINDOW PANEL BORDER AND DOOR FRAME 

AND LIP 

REMOVE TOP PAINT FOR A BAND EQUAL T O 9 mm 

TYP LH AND RH 

IT IS FORBIDDEN TO STRETCH THE 

FILLER TO DEFORM THE SECTION. 

TO MAKE INSTALLATION EASIER 

TYP LH AND RH 

INSTALL WINDOW WITH; 

999-1700-48-101G SEAL (L 2320 mm) 

999-1700-49-101 G FILLER (L. 2320 mm) 

TYP LH AND RH 

Page 12 of 19 

SECTJON A-A 

FILLER LOCATION INSIDE SURFACE OF DOOR 

TYP LH AND RH 

BOND SEAL ON FUSELAGE SIDE ONLY 

WITH 199-05-1 52 TY I CL 2 (RTV 732) 

OVER T HE ENTIRE PERIMETER 

TYP LH AND RH 

SECTION A-A 

Figure 3 
B.T. 139-129 Rev./ 

KNURLED GROOVE 

(WINDOW SIDE) 

SEAL P/N 999-1700-48-1 01 G 

/ COCKPIT DOOR WINDOW 

COCKPIT DOOR FRAME ... 

FILLER WEDGE 

.....--- P/N 999-1700-49-101 G 

SEAL P/N 999-1700-48-101G 

INSTALLED 

Figure 4 

Page 13 of 19 
B.T. 139-129 Rev. / 

6 x2 

8 x2 

7 

@(3 8 

~~/ 5 

4 

) 

~ 2x2 

3 

~ ~ 

e~ 

{ 

Figure 5 

Page 14 of 19 

1 
B.T. 139-129 Rev./ 

Figure 6 

Figure 7 

Page 15 of 19 
B.T. 139-129 Rev. / 

Figure 8 

Page 16 of 19 
B.T. 139-129 Rev. I 

Figure 9 

Page 17 of 19 
B.T. 139-129 Rev./ 

MS27980-178 snuo 

NA5114900363K UA9-ER 

NASI832 -3-3 INSERT 

SCHEMATIC SECTION J-J 

SHOWN FOR REFERENCE ONLY 

3G56 1 OA4 751 STRAP 

Page 18 of 19 

A436A06A2 NUT 

A994A15T0100 ~ASHER (2PQS ) H535207-230 BOLT 

SECTION Z-Z 

Figure 10 
VIEW FROM 

OUTER SIDE 2 / 

I / I 

-...,:- :. 

r'.S . .. 

EMERGENCY EXIT 

PUSH WINDOW 

AT LOWER CORNER 

Figure 11 

B.T. 139-129 Rev. / 

VIEW FROM 

INNER SIDE 

' 

) 

, 

Page 19 of 19